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At least 1,027 records · Page 57

James Webb Space Telescope Integrated Science Instrument Module Thermal Vacuum Thermal Balance Test Campaign at NASA's Goddard Space Flight Center

The James Webb Space Telescope is a large infrared telescope with a 6.5-meter primary mirror, designed as a successor to the Hubble Space Telescope when launched in 2018. Three of the four science instruments contained within the Integrated Science Instrument Module (ISIM) are passively cooled to their operational temperature range of 36K to 40K with radiators, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. Thermal-vacuum testing of the flight science instruments at the ISIM element level has taken place in three separate highly challenging and extremely complex thermal tests within a gaseous helium-cooled shroud inside Goddard Space Flight Centers Space Environment Simulator. Special data acquisition software was developed for these tests to monitor over 1700 flight and test sensor measurements, track over 50 gradients, component rates, and temperature limits in real time against defined constraints and limitations, and guide the complex transition from ambient to final cryogenic temperatures and back. This extremely flexible system has proven highly successful in safeguarding the nearly $2B science payload during the 3.5-month-long thermal tests. Heat flow measurement instrumentation, or Q-meters, were also specially developed for these tests. These devices provide thermal boundaries o the flight hardware while measuring instrument heat loads up to 600 mW with an estimated uncertainty of 2 mW in test, enabling accurate thermal model correlation, hardware design validation, and workmanship verification. The high accuracy heat load measurements provided first evidence of a potentially serious hardware design issue that was subsequently corrected. This paper provides an overview of the ISIM-level thermal-vacuum tests and thermal objectives; explains the thermal test configuration and thermal balances; describes special measurement instrumentation and monitoring and control software; presents key test thermal results; lists problems encountered during testing and lessons learned.

JWST ISIM Thermal↗

Simulation capability for dynamics of rotating counterweight space stations.

An analysis and computer program were prepared to realistically simulate the dynamic behavior of a class of space stations consisting of two end bodies separated by a connecting structure. The shape and mass distribution of the flexible end bodies are arbitrary; the connecting structure is flexible but massless and is capable of deployment and retraction. Fluid flowing in a piping system and rigid moving masses, representing a cargo elevator or crew members, have been modeled. Connecting structure characteristics, control systems, and externally applied loads are modeled in easily replaced subroutines. Subroutines currently available include a telescopic beam-type connecting structure as well as attitude, deployment, spin, and wobble control. In addition, a unique mass balance control system was developed to sense and balance mass shifts due to the motion of a cargo elevator. The mass of the cargo may vary through a large range. Numerical results are discussed for various types of runs.

Austin, F.↗

Simulation capability for dynamics of two-body flexible satellites

An analysis and computer program were prepared to realistically simulate the dynamic behavior of a class of satellites consisting of two end bodies separated by a connecting structure. The shape and mass distribution of the flexible end bodies are arbitrary; the connecting structure is flexible but massless and is capable of deployment and retraction. Fluid flowing in a piping system and rigid moving masses, representing a cargo elevator or crew members, have been modeled. Connecting structure characteristics, control systems, and externally applied loads are modeled in easily replaced subroutines. Subroutines currently available include a telescopic beam-type connecting structure as well as attitude, deployment, spin and wobble control. In addition, a unique mass balance control system was developed to sense and balance mass shifts due to the motion of a cargo elevator. The mass of the cargo may vary through a large range. Numerical results are discussed for various types of runs.

Austin, F.↗

An extension of the local momentum theory to a distorted wake model of a hovering rotor

The local momentum theory is based on the instantaneous balance between the fluid momentum and the blade elemental lift at a local station in the rotor rotational plane. Therefore, the theory has the capability of evaluating time wise variations of air loading and induced velocity distributions along a helicopter blade span. Unlike a complex vortex theory, this theory was developed to analyze the instantaneous induced velocity distribution effectively. The boundaries of this theory and a computer program using this theory are discussed. A concept introduced into the theory is the effect of the rotor wake contraction in hovering flight. A comparison of this extended local momentum theory with a prescribed wake vortex theory is also presented. The results indicate that the extended local momentum theory has the capability of achieving a level of accuracy similar to that of the prescribed wake vortex theory over wide range variations of rotor geometrical parameters. It is also shown that the analytical results obtained using either theory are in reasonable agreement with experimental data.

Kawachi, K.↗

NASA Tech Briefs, September 2012

Topics covered include: Beat-to-Beat Blood Pressure Monitor; Measurement Techniques for Clock Jitter; Lightweight, Miniature Inertial Measurement System; Optical Density Analysis of X-Rays Utilizing Calibration Tooling to Estimate Thickness of Parts; Fuel Cell/Electrochemical Cell Voltage Monitor; Anomaly Detection Techniques with Real Test Data from a Spinning Turbine Engine-Like Rotor; Measuring Air Leaks into the Vacuum Space of Large Liquid Hydrogen Tanks; Antenna Calibration and Measurement Equipment; Glass Solder Approach for Robust, Low-Loss, Fiber-to-Waveguide Coupling; Lightweight Metal Matrix Composite Segmented for Manufacturing High-Precision Mirrors; Plasma Treatment to Remove Carbon from Indium UV Filters; Telerobotics Workstation (TRWS) for Deep Space Habitats; Single-Pole Double-Throw MMIC Switches for a Microwave Radiometer; On Shaft Data Acquisition System (OSDAS); ASIC Readout Circuit Architecture for Large Geiger Photodiode Arrays; Flexible Architecture for FPGAs in Embedded Systems; Polyurea-Based Aerogel Monoliths and Composites; Resin-Impregnated Carbon Ablator: A New Ablative Material for Hyperbolic Entry Speeds; Self-Cleaning Particulate Prefilter Media; Modular, Rapid Propellant Loading System/Cryogenic Testbed; Compact, Low-Force, Low-Noise Linear Actuator; Loop Heat Pipe with Thermal Control Valve as a Variable Thermal Link; Process for Measuring Over-Center Distances; Hands-Free Transcranial Color Doppler Probe; Improving Balance Function Using Low Levels of Electrical Stimulation of the Balance Organs; Developing Physiologic Models for Emergency Medical Procedures Under Microgravity; PMA-Linked Fluorescence for Rapid Detection of Viable Bacterial Endospores; Portable Intravenous Fluid Production Device for Ground Use; Adaptation of a Filter Assembly to Assess Microbial Bioburden of Pressurant Within a Propulsion System; Multiplexed Force and Deflection Sensing Shell Membranes for Robotic Manipulators; Whispering Gallery Mode Optomechanical Resonator; Vision-Aided Autonomous Landing and Ingress of Micro Aerial Vehicles; Self-Sealing Wet Chemistry Cell for Field Analysis; General MACOS Interface for Modeling and Analysis for Controlled Optical Systems; Mars Technology Rover with Arm-Mounted Percussive Coring Tool, Microimager, and Sample-Handling Encapsulation Containerization Subsystem; Fault-Tolerant, Real-Time, Multi-Core Computer System; Water Detection Based on Object Reflections; SATPLOT for Analysis of SECCHI Heliospheric Imager Data; Plug-in Plan Tool v3.0.3.1; Frequency Correction for MIRO Chirp Transformation Spectroscopy Spectrum; Nonlinear Estimation Approach to Real-Time Georegistration from Aerial Images; Optimal Force Control of Vibro-Impact Systems for Autonomous Drilling Applications; Low-Cost Telemetry System for Small/Micro Satellites; Operator Interface and Control Software for the Reconfigurable Surface System Tri-ATHLETE; and Algorithms for Determining Physical Responses of Structures Under Load.

Source record↗

Multi-Anode Frequency Triplers at Sub-Millimeter Wavelengths

We report on the design methodology of fix-tuned split-block waveguide balanced frequency triplers working at 300,600 and 900 GHz. They feature four to six GaAs Schottky planar diodes in a balanced configuration. A 6-anode 300 GHz tripler, a 6-anode 560 GHz tripler and a 4-anode 900 GHz tripler will be fabricated with JPL membrane technology in order to minimize dielectric loading and ensure accurate thickness of the substrate. A 4-anode 600 GHz tripler was fabricated with JPL substrateless technology that delivers 0.8-1.6mW in the 540-640 GHz band at room temperature. When cooled to l2OK this tripler delivers 2-4mW from 540 to 640 GHz.

Schottky diodes↗

Performance Evaluation and Optimal Design Analysis of Continuous-Operation Solar-Driven Cooling Absorption Systems With Thermal Energy Storage

A solar absorption cooling system consisting of a flat plate collector, thermal energy storage tank, and absorption chiller is analyzed in this work. A dimensionless model is developed from the energy balance on each component and the chiller's characteristic performance curves. The model is used to determine the interaction and influence of different parameters such as tank size, solar collector area, chiller size, cooling load, cooling temperature, heat loss, and mass flow rates on the performance. From the analysis, smaller solar collector areas are required for lower cooling loads and smaller tank volumes. A specific cooling load of 1 x 10^-5 will require a specific solar collector area between two and six times larger, depending on the initial tank temperature, than the area required for a baseline system that considers typical commercial design and operation parameters. A similar behavior was observed for the specific tank volume. For the baseline system, the minimum specific area of the collector of 9.57 is achieved for an initial tank temperature of 1.19. For a cooling load of 1 x 10^-5, the optimum initial tank temperature will be 1.11 that results in a minimum specific solar collector area of 25.26. A specific tank volume of 4 x 10^-4 will also have an optimum initial tank temperature of 1.11 that minimizes the specific solar collector area to a value of 28.18. The approach and analysis in this work can be used to determine design parameters for solar absorption cooling systems based on a proper relation among system's dimensions to achieve optimum operation.

cooling load↗

Digital Real-Time Simulation and Power Quality Analysis of a Hydrogen-Generating Nuclear-Renewable Integrated Energy System

This paper investigates the challenges and solutions associated with integrating a hydrogen-generating nuclear-renewable integrated energy system (NR-IES) under a transactive energy framework. The proposed system directs excess nuclear power to hydrogen production during periods of low grid demand while utilizing renewables to maintain grid stability. Using digital real-time simulation (DRTS) in the Typhoon HIL 404 model, the dynamic interactions between nuclear power plants, electrolyzers, and power grids are analyzed to mitigate issues such as harmonic distortion, power quality degradation, and low power factor caused by large non-linear loads. A three-phase power conversion system is modeled using the Typhoon HIL 404 model and includes a generator, a variable load, an electrolyzer, and power filters. Active harmonic filters (AHFs) and hybrid active power filters (HAPFs) are implemented to address harmonic mitigation and reactive power compensation. The results reveal that the HAPF topology effectively balances cost efficiency and performance and significantly reduces active filter current requirements compared to AHF-only systems. During maximum electrolyzer operation at 4 MW, the grid frequency dropped below 59.3 Hz without filtering; however, the implementation of power filters successfully restored the frequency to 59.9 Hz, demonstrating its effectiveness in maintaining grid stability. Future work will focus on integrating a deep reinforcement learning (DRL) framework with real-time simulation and optimizing real-time power dispatch, thus enabling a scalable, efficient NR-IES for sustainable energy markets.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Exploratory tests of a simple aero-mechanical ride comfort system for lightly loaded aircraft

Some exploratory wind tunnel and radio-controlled free-flight tests were made with a small high-wing airplane model (1.23m wing span) to study the concept of a simple aero mechanical system intended to alleviate gust loads and improve ride comfort of lightly loaded aircraft. The system consisted essentially of the outer portions of each wing being hinged in the chordwise direction and connected directly to the wing flaps using internal counter weights to provide neutral mass balance. When the wing experienced a change in velocity or angle of attack, the movable wing panels, acting as sensors and flap actuators, deflected in response to the changes in lift on the wing. The corresponding movements of the interconnected flaps tended to reduce the changes in the wing lift.

Hewes, D. E.↗

Stabilizing the Grid and Reducing Utility Bills Through Price-Responsive Controls for Heat Pump Water Heaters

The electricity grid is facing increasing challenges in cost-effectively balancing supply and demand. These challenges are exacerbated by increased penetration of photovoltaics, which causes mid-day overproduction, and electrification of gas appliances, which increases peak-period electricity demand. Decarbonization requires shifting building loads from fossil-intensive high-cost times to renewable-intensive low-cost times while maintaining quality of service to occupants. Utilities and ISO’s are investigating new ways of incentivizing this load shifting. One promising method is the use of Highly Dynamic Prices (HDPs). HDPs feature continuously changing prices that reflect real-time grid generation and distribution costs and capacity constraints, and thus incentivize consumers to shift their loads. California’s CPUC CalFUSE proposal and Hawaii’s recent changes demonstrate that electricity tariffs are moving towards this model. For this to work however, loads must have the capability to respond to these prices. Heat pump water heaters (HPWHs) are an ideal device for this purpose because their storage tanks decouple delivery of domestic hot water from electricity consumption. The storage enables control strategies that consume midday solar power to increase the energy stored in the tank, then provide evening peak domestic hot water services using the stored energy. Berkeley Lab's CalFlexHub project is pioneering price-driven load flexibility by developing and deploying cost-minimizing controls for many flexible loads - including HPWHs - in response to HDP. Control development is based on simulations using the Flexible Heat Pump Water Heater Performance Predictor which captures the control decisions of the on-board controller in a residential, integrated HPWH . The price-responsive controls a) shift load in ways that consume additional midday solar power to help stabilize the grid and reduce overall emissions, b) ensure that occupants receive equal or better hot water delivery service, and c) minimize the operating cost for each home in the fleet. On the grid level, the resulting shift will reduce utility operating costs and emissions, and can avoid expensive system capacity expansions. The control approach is customized to each home based on typical hot water consumption patterns. HPWH controllers, whether on the device or remotely, will receive a schedule of CTA-2045-B signals or set temperature adjustments customized to the current HDP price schedule and home. Simulation results for a fleet of 148 HPWHs on a summer day in Berkeley, California show cost savings of 29% and high price electricity consumption reductions of 80%, while maintaining full quality of service.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Flying Schedule-Matching Descents to Explore Flight Crews' Perceptions of Their Load and Task Feasibility

Multiple studies have investigated the development and use of ground-based (controller) tools to manage and schedule traffic in future terminal airspace. No studies have investigated the impacts that such tools (and concepts) could have on the flight-deck. To begin to redress the balance, an exploratory study investigated the procedures and actions of ten Boeing-747-400 crews as they flew eight continuous descent approaches in the Los Angeles terminal airspace, with the descents being controlled using speed alone. Although the study was exploratory in nature, four variables were manipulated: speed changes, route constraints, clearance phraseology, and winds. Despite flying the same scenarios with the same events and timing, there was at least a 50 second difference in the time it took crews to fly the approaches. This variation is the product of a number of factors but highlights potential difficulties for scheduling tools that would have to accommodate this amount of natural variation in descent times. The primary focus of this paper is the potential impact of ground scheduling tools on the flight crews performance and procedures. Crews reported "moderate to low" workload, on average; however, short periods of intense and high workload were observed. The non-flying pilot often reported a higher level of workload than the flying-pilot, which may be due to their increased interaction with the Flight Management Computer, when using the aircraft automation to assist with managing the descent clearances. It is concluded that ground-side tools and automation may have a larger impact on the current-day flight-deck than was assumed and that studies investigating this impact should continue in parallel with controller support tool development.

Martin, Lynne Hazel↗

Radiative Effects of Aerosols Generated from Biomass Burning, Dust Storms, and Forest Fires

Atmospheric aerosol particles, both natural and anthropogenic, are important to the earth's radiative balance. They scatter the incoming solar radiation and modify the shortwave reflective properties of clouds by acting as Cloud Condensation Nuclei (CCN). Although it has been recognized that aerosols exert a net cooling influence on climate (Twomey et al. 1984), this effect has received much less attention than the radiative forcings due to clouds and greenhouse gases. The radiative forcing due to aerosols is comparable in magnitude to current anthropogenic greenhouse gas forcing but opposite in sign (Houghton et al. 1990). Atmospheric aerosol particles generated from biomass burning, dust storms and forest fires are important regional climatic variables. A recent study by Penner et al. (1992) proposed that smoke particles from biomass burning may have a significant impact on the global radiation balance. They estimate that about 114 Tg of smoke is produced per year in the tropics through biomass burning. The direct and indirect effects of smoke aerosol due to biomass burning could add up globally to a cooling effect as large as 2 W/sq m. Ackerman and Chung (1992) used model calculations and the Earth Radiation Budget Experiment (ERBE) data to show that in comparison to clear days, the heavy dust loading over the Saudi Arabian peninsula can change the Top of the Atmosphere (TOA) clear sky shortwave and longwave radiant exitance by 40-90 W/sq m and 5-20 W/sq m, respectively. Large particle concentrations produced from these types of events often are found with optical thicknesses greater than one. These aerosol particles are transported across considerable distances from the source (Fraser et al. 1984). and they could perturb the radiative balance significantly. In this study, the regional radiative effects of aerosols produced from biomass burning, dust storms and forest fires are examined using the Advanced Very High Resolution Radiometer (AVHRR) Local Area Coverage (LAC) data and the instantaneous scanner ERBE data from the NOAA-9 and NOAA-10 satellites.

Christopher Sundar A.↗

A Review of Behind-the-Meter Solar Generation Modeling and Forecasting

Solar photovoltaic systems largely integrated within the distribution grid are operated 'behind-the-meter' and power generation cannot be directly monitored by most utilities. The increasing penetration of behind-the-meter solar photovoltaic systems can deter efficient network and market operations due to variability and uncertainty in net load, which is exacerbated by limited visibility and the difficulty in analyzing the hosting capacity. Risk introduced by behind-the-meter solar contributions may hinder reliable and secure grid operations due to biased system monitoring and forecasts. Accurate behind-the-meter estimations, together with capacity and specification forecasts, thus play a key role in balancing supply and demand and this article reviews the pertinent literature, identifying key characteristics and predictive methods for efficient behind-the-meter solar photovoltaic generation. Forecasting is central to methods herein. The fundamental characteristics of behind-the-meter solar forecasting, including which methods are applicable for scenario-driven use cases, are driven by the metrics most useful for system-wide performance evaluation. To this aim, the literature is reviewed with a focus on forecasting applications for aggregate, regional behind-the-meter generation useful to bulk system and utility operations. As distinguished from net load forecasting, subtleties in these coincident tasks are explored before concluding with recommendations for current practice and future implementations.

behind-the-meter↗

A Micromorphic Length-Scale Coupling Framework for the Determination of Higher-Order Constitutive Models and the Multi-Scale Simulation of Heterogeneous Materials [Thesis]

Heterogeneous materials and materials with complex microstructures pose a unique challenge in the development of accurate models of their response to external stimuli. These difficulties principally arise due to the difficulty in characterizing and modeling the constituents and their interactions. It is usually possible, though non-trivial, to construct an explicit representation of the microstructure (a direct numeric simulation or DNS) but the method by which the complex modes of deformation and other processes can be homogenized to a reduced-order approximation is frequently unclear. Many homogenization approaches are ad-hoc and lack a strong justification beyond ease of computation. Furthermore, the homogenization approach can, in some cases, not utilize the full breadth of information available in the computation of the macro-scale stresses and deformation measures. It is also noteworthy that homogenization, by its very nature, will tend to obfuscate details of processes occurring at the lower length-scale. It is therefore of interest to include as much information as possible in the construction of the reduced-order model so as to be predictive in a variety of loading environments. We here present a length-scale bridging technique based upon the micromorphic continuum mechanics of Eringen which incorporates volume and surface area averages as a part of its construction. This approach enforces the balance equations at the micro-scale and then studies the effect of the spatially varying nature on the macro-scale. This leads, naturally, to further balance equations which are solved at the macro-scale. This work details a homogenization framework which arises naturally from the micromorphic construction of Eringen attempting to introduce no definitions beyond which are justifiable from micro-structural considerations. One of the results of this effort is the so-called “micromorphic filter” which has been developed and applied to several DNS to demonstrate its effectively. In order to determine the macroscopic degrees of freedom we utilize the special case of an overlap coupling technique where the macro-scale is fully constrained to the micro-scale. This enables us to study the resulting material properties as expected but also allows us to further study the boundary conditions on the additional degrees of freedom at the macro-scale.

42 ENGINEERING↗

Value of Nuclear Energy to the Reliability of the North American Power System: Results for Western and Eastern Interconnections

This report documents the fulfillment of a milestone for the United States (U.S.) Department of Energy Office of Nuclear Energy Light Water Reactor Sustainability Program: completing a baseline study of regional impact of nuclear power plants and hydrogen production in maintaining grid services and power quality. Models have been comprehensively demonstrated for the Western Interconnection, or Western Electric Coordinating Council area, and in the Eastern Interconnection for scenarios representative of past extreme events (e.g., drought and heat waves). Understanding the impact on the reliability of the bulk electric system of any reduction in generation capacity from nuclear power, for any reason, is the motivation of this work. Factors that might lead to the premature or unplanned closure of nuclear plants, extended outages, or repurposing of nuclear power include: • Aging infrastructure: Many nuclear power plants in the U.S. are nearing the end of their designed operating lives. Upgrading aging infrastructure can be expensive, and some utilities may choose to retire plants rather than invest in costly upgrades. • Low wholesale electricity prices: The deregulation of the electricity market in many states has led to increased competition and driven down wholesale electricity prices, causing nuclear power operators to seek other revenue sources for their heat and power such as clean hydrogen production. • Renewables growth: The rapid growth of renewable energy sources like solar and wind power is posing a challenge to traditional generation sources like nuclear. While many see renewables as a key part of the clean energy transition, their intermittent nature requires additional grid solutions for reliable power supply. • The potential for regulatory decisions to be in conflict: In its 2021 rulemaking, EPA rule (86 FR 880), the Environmental Protection Agency (EPA) set a compliance date for the ban on processing and distribution in commerce of Decabromodiphenyl Ether (DecaBDE). Since DecaBDE is in many components, particularly wiring, of nuclear power plants which are deemed safety-related or important to safety, three plants would not have been able to restart after their 2023 spring outages, and numerous others would have faced issues in the near future. Fortunately, in this case, the EPA provided relief to the nuclear energy industry. The report provides a summary of the significant role nuclear energy plays in the United States’ power generation mix, supplying around 20% of the nation’s electricity generation, spread across 28 U.S. states. Nuclear power is reliable, mostly unaffected by weather and seasonal changes, and provides a consistent source of baseload power. In terms of capacity, nuclear power plants account for as much as 26% of balancing area power generation capacity. Nuclear power also provides a substantial contribution (e.g., 10% of the inertia in the Eastern Interconnection) of the synchronous spinning mass/inertia that buffers the rate at which frequency changes when a load and generation imbalance occurs (e.g., a large plant trips or a load is suddenly shed due to a transmission outage). This contribution is critical for maintaining grid stability during sudden changes in load or generation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Nonlinear analysis of laminated fibrous composites

A computerized analysis of the nonlinear behavior of fibrous composite laminates including axial loading, thermal loading, temperature dependent properties, and edge effects is presented. Ramberg-Osgood approximations are used to represent lamina stress-strain behavior and percent retention curves are employed to model the variation of properties with temperature. Balanced, symmetric laminates comprised of either boron/epoxy, graphite/epoxy, or borsic-aluminum are analyzed using a quasi-three-dimensional finite element analysis. Results are presented for the interlaminar stress distributions in cross-ply, angle-ply, and more complex laminates. Nonlinear stress-strain curves for a variety of composite laminates in tension and compression are obtained and compared to other existing theories and experimental results.

Renieri, G. D.↗

A theoretical study of resin flows for thermosetting materials during prepreg processing

A flow model which describes the process of resin consolidation during prepreg lamination was developed. The salient features of model predictions were explored. It is assumed that resin flows in all directions originate from squeezing action between two approaching adjacent fiber/fabric layers. In the horizontal direction, a squeezing flow between two nonporous parallel plates is analyzed, while in the vertical direction a poiseuille type pressure flow through porous media is assumed. Proper force and mass balance was established for the whole system which is composed of these two types of flow. A flow parameter, CF, shows to be a measure of processibility for the curing resin. For a given external load-F the responses of resin flow during prepreg lamination, as measured by CF, are categorized into three regions: (1) the low CF region where resin flows are inhibited by the high chemoviscosity during initial curing stages; (2) the median CF region where resin flows are properly controllable; and (3) the high CF region where resin flows are ceased due to fiber/fabric compression effects. Resin losses in both directions are calculated. Potential uses of this model and quality control of incoming prepreg material are discussed.

Hou, T. H.↗

Design of a Wind Tunnel Balance using Topology Optimization Considering Multifunctional Stress Performance

This paper proposes a new topology optimization formulation for multi-functional performance of a compliant sensor structure–a wind tunnel balance. Compliant mechanism design is one of the main applications of topology optimization and plenty of successful design studies have been reported. However, design practicability is still questionable when stress concentration is critical due to complex/combined loads, especially at compliant hinge joints. In this paper, we formulate a new topology optimization formulation considering multiple loading scenarios in a compliant sensor structure design. Two separate constraints,one related to sensor performance and the other focused on structural safety in terms of maximum von Mises stress, are included in the design formulation. This formulation is to achieve excellent sensitivity of an applied axial load while maintaining structure safety with a combined general load applied which is one order higher than the axial load. This challenging problem is solved using a well-known SIMP approach with the relaxation and projection methods.

Myung Kyun Sung↗